Support panel for masonry

ABSTRACT

A support panel for masonry objects that includes an inner surface, an outer surface, at least one stiffening channel formed longitudinally along the support panel, a plurality of substantially c-shaped claws extending from the outer surface, the claws being disposed in spaced apart relation to one another to form a grid, wherein the claws are configured to contactingly support at least a portion of a masonry object, and wherein the support panel is attachable to a wall of a structure via at least one fastener inserted into through the at least one stiffening channel into the wall of the structure such that the panel is spaced apart from the wall of the structure.

CROSS-REFERENCE TO RELATED APPLICATION(S)

This application claims the benefit of U.S. Provisional Application Ser.No. 61/210,758, filed Mar. 23, 2009, entitled “SUPPORT PANEL FORMASONRY,” which is hereby incorporated herein by reference in itsentirety, including all references cited therein.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to panels for supporting masonry, such asbrick or stone veneers.

2. Background Art

Thin brick and stone have been around for thousands of years. In thelate 1700's, metal lathe was invented and used to support masonry onbuildings and other structures. The use of metal lathe as a masonrysupport was introduced into the United States in the mid 1800's. Themetal lathe was anchored to a wall of a building or structure, and thenthe cut brick or stone was bonded to the lathe and wall using a cement.This method, although reliable, was very labor intensive. Once the metallathe was attached to the wall, workers would trowel the cement to thelathe and then lay the brick or stone into the cement. The latheprovided no guidance as to the placement and spacing of the brick orstone, and therefore, the workers would have to space every brick orstone one by one. The workers would either “eyeball” the spacing, or useimplements for properly spacing the brick, such as pieces of wood,lengths of rope (which may be pulled out between the spacing before thecement sets) or even the worker's finger.

The metal lathe was in the form of a mesh or netting which was affixedto the wall of the building. The mortar or cement which was applied tothis metal lathe mesh, with the brick or stone placed on the mortar,formed a solid backing which never allowed moisture to travel downwardlyby gravity either between the wall and the lathe or the brick and themortar. This trapped any moisture in pockets formed by gaps in trowelingthe mortar. This moisture would freeze and thaw with variations in thetemperature, resulting in expansion and contraction, which would “pop”the brick or stone, causing it to loosen and possibly fall from the wallof the building or structure.

In the 1920's, the Klinglehut Corporation conceived the idea of gluingbrick to an asphalt soft board. This board is an asphalt product,similar in some respect to a fiberboard, which is slightly compressible(that is, not as hard as metal or plywood). This board would be screwedonto the wall of the building or structure in substitution for the metallathe. The brick or stone was then adhered to the board by using anadhesive. This adhesive would be similar to a construction cement, suchas what is used when laminating plywood layers together or which is usedfor marine applications, and provides a very strong bond between thesoft board and the brick or stone. Then, a mortar or cement is appliedbetween the brick or stone glued to the soft board. This system wasconsidered the first thin brick system, that is, using a brick veneer,which is generally about one-half inch in depth. This method was usedfor several decades.

In the 1970's, it became popular to use a method of attaching thin brickto foam panels using metal clips. The foam panels were similar toinsulation board, such as those made by Dow Corning. With this method,the foam boards or panels were screwed into the wall of the building orstructure. The foam panels had recessed channels formed horizontally inthe outer surface of the panels, the transverse width of each channelbeing slightly greater than the width of the bricks. These channels arewhere the spaced apart bricks would be placed in a horizontal row, thusproviding guidance for the bricklayer as to the placement of the brickon the support foam panels. Metal clips were placed on the outer surfaceof the foam panels and periodically spaced vertically and horizontallyon the panels. The clips were L-shaped brackets which were about threeinches wide by about two inches high. A vertical leg portion of the cliphad a hole in which a screw passed through to fasten the foam board orpanel to the wall of the building. A horizontal leg portion of the clipextended from the vertical portion outwardly from the outer surface ofthe foam panel. An adhesive was applied in one continuous serpentineline within each recessed channel of the foam boards, and the brickswere then placed in a horizontal row within each channel to contact theadhesive within the channel so that the brick bonded to the foam panelsby the adhesive. Then, the cement or mortar was applied to the spacingbetween adjacent bricks both vertically and horizontally. The outwardlyextending leg of each clip held the mortar in place after it had dried.The clips were spaced a predetermined distance from each other, as eachclip was designed to support a certain square footage of mortar. Themortar, when applied, would actually wrap around the leg portion of theclips extending outwardly from the support panel, and this is what wouldsupposedly keep the mortar in place on the wall. Thus, the clips were tointerlock with the mortar, creating a mechanical support system.

There were several disadvantages using the foam panel system describedabove. The foam would ultimately deteriorate due to a chemical reactionwith the mortar. Furthermore, the way in which the adhesive was applied,in a continuous serpentine line horizontally within each channel,created a dam that prevented moisture that collected behind the brickfrom flowing downwardly by gravity. Since the water would now collectbehind the bricks, freezing and thawing of the water would cause thebricks to loosen. Furthermore, the channels which are formed in theouter surface of the foam panels in which horizontal rows of brick areplaced create additional dams that prevent water and moisture fromflowing downwardly by gravity between the foam panels and the bricksmounted on the foam panels. Again, this moisture and water collectingbehind the bricks would freeze and expand, causing the bricks to loosen.

In the 1980's, the same concept of attaching thin brick described abovebut now using metal panels came into existence. The metal panels wouldhave continuous rails running horizontally across the panels forsupporting the bricks. The bricks were glued to the outer surface of themetal panels, and mortar was applied between bricks. This concept stillhad flaws. The continuous horizontally disposed rails along the panelstill trap the moisture behind the brick, as the moisture and watercould not flow downwardly due to the rails, and this sometimes forcedthe brick to loosen when a freeze/thaw cycle (when the temperaturefluctuates below and above freezing) occurred. Furthermore, with thissystem, the panel laid flush on the wall of the building or structure,and thus did not provide an air/vapor cavity. An air/vapor cavity isimportant in order to allow moisture to escape and have an air flowbetween the panel and the wall to prevent the wall from deteriorating byrotting.

In the evolution of the masonry supporting system, the next change wasto eliminate the rails and include periodically vertically andhorizontally spaced apart, half moon-shaped tabs extending outwardlyfrom the outer surface of the support panels. The tabs are spaced fromeach other, vertically, slightly greater than the width of the bricks,and the bricks are received between the vertically adjacent tabs. Eachbrick was attached to the outer surface of the support panel usingadhesive placed in the four corners of the brick, and the brick was thenpositioned on the outer face of the support panel between verticallyadjacent half moon-shaped tabs. Mortar was then applied to the verticaland horizontal spaces between adjacent bricks. One of the problems withthis system was that the mortar never truly attached to the halfmoon-shaped tabs, and thus never created a mechanical bond with thepanel. This system overcame some disadvantages of prior systems. Theadhesive, being placed in the four corners of the brick, separated thebrick from the panel a distance, such as one quarter inch, that allowedmoisture and water to flow by gravity downwardly between the panels andthe bricks mounted thereon, and through weep holes formed at the base ofthe brick veneer.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a front view of a panel used for supporting masonry, such asbrick or stone, formed in accordance with the present invention.

FIG. 2 is a top plan view of the support panel of the present inventionshown in FIG. 1.

FIG. 3 is a top view of a claw formed in accordance with the presentinvention which extends outwardly from the outer surface of the supportpanel of the present invention shown in FIGS. 1 and 2.

FIG. 4 is a front view of the claw formed on the support panel of thepresent invention and shown in FIG. 3, with a corresponding punched holeformed through the support panel being illustrated by hatched lines.

FIG. 5 is a side view of a portion of the support panel, building wall,bricks and mortar, and illustrating the claw formed in accordance withthe present invention and shown in FIGS. 3 and 4.

FIG. 6 is a top view of a portion of the support panel, building walland a brick, such as shown in FIG. 5 of the drawings, and illustratingthe claw formed in accordance with the present invention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

In accordance with one form of the present invention, and as shown inFIGS. 1-6 of the drawings, a panel for supporting masonry, such as brickor stone veneers, is preferably made from a 27 gauge architectural gradesteel panel. The panel size is nominally 48 inches by 48 inches,although it is envisioned to be within the scope of the presentinvention to form the steel panels with different sizes and fromdifferent gauge steel.

As seen in FIG. 2 of the drawings, each panel has a plurality ofvertical stiffening channels which are spaced apart parallelly from eachother at preferably about a 4 inch spacing so that a respectivestiffening channel will be in alignment with a vertical stud of the wallof the building or structure to which the panel is mounted, such studsbeing spaced apart from each other about 16 inches measuredcenter-to-center, in accordance with industry standards.

Preferably, the vertical stiffening channels are formed as an integralpart of the steel panel by deforming the steel panel to form thestiffening channels. In effect, therefore, the vertical stiffeningchannels are recessed portions of the outer surface of the panel whichextend outwardly from the opposite inner surface of the panel apredetermined distance, such as one half inch. The vertical stiffeningchannels are spaced apart horizontally from each other anotherpredetermined distance, such as about two feet.

The vertical stiffening channels may include a plurality of holessituated along the length thereof and formed through the thickness ofthe panel, with adjacent holes spaced apart from each other apredetermined distance. Such holes are provided to accept a fastener,such as screws or nails, therethrough to mount the support panel to asupporting structure, such as the vertical studs of the building.Furthermore, the vertical stiffening channels allow the support panel tobe mounted away from the wall of the building or structure and,therefore, provide an air/vapor cavity between the wall and the supportpanel to allow air and moisture to flow through this cavity. Thevertical stiffening channels thus keep the panel away from the wall andallow equalization of air pressure behind the wall, thus guaranteeingconstant air flow.

Another feature of the vertical stiffening channels, as its nameimplies, is to stiffen the panel to minimize its bending across thewidth and length thereof. Furthermore, since each vertical stiffeningchannel is formed as a recessed portion of the outer surface of thepanel, the vertical stiffening channels provide a path for moisture andwater to flow from between the outer surface of the panel and the innersurface of the bricks attached thereto.

Preferably, each support panel has a G90 galvanization ratingaccompanied by a two coat, thermo set, siliconized polyester paintfinish to minimize rusting. Furthermore, the outer surface (and, ifdesired, the inner surface) of the support panel includes astucco-embossed texture having raised and lowered portions. This textureserves two purposes. First, the texture adds more surface area to whichthe adhesive used to attach the brick to the support panel may bond.Second, the texture on the outer surface and the inner surface of thesupport panel provides a path for moisture to constantly traveldownwardly, by gravity, between the brick and the support panel, therebypreventing moisture from accumulating behind the brick or stone mountedto the support panel, and provides a path for moisture to traveldownwardly on the inner surface of the support panel which faces thebuilding wall.

Preferably, an adhesive is used to bond the brick or stone to thesupport panel. A small one quarter inch dab of adhesive is placed ateach corner of the brick on the rear surface thereof, and the brick isthen placed against the support panel between vertically adjacent claws,as will be described in greater detail. The adhesive maintains thespacing between the brick and the support panel to allow moisture orwater to flow downwardly by gravity between the outer surface of thesupport panel and the inner surface of the brick secured thereto.

FIGS. 4-6 illustrate the preferred form of each claw of the plurality ofclaws situated on the outer surface of the support panel. The claws areformed by a die punching through the thickness of the support panel fromthe inner surface of the support panel to the outer surface. Each clawincludes a horizontal leg, and two oppositely disposed lateral legsextending from and in front of the horizontal leg, and joined to thefront edge thereof near axial end portions of the horizontal leg. Thehorizontal leg and lateral legs preferably reside in the same plane andare formed from the same partially punched-out portion of the supportplate. Overall, each claw has a semi-circular shape. Thus, each clawremains affixed to the support panel, and is bent outwardly from theouter surface thereof at a predetermined angle. The free ends of thelateral legs are spaced apart from each other a predetermined distance(preferably 0.1875 inches), and are positioned in front of the outermostedge of the horizontal leg to define therebetween a pocket or cavity forreceiving mortar and to insure that the mortar adheres to each clawformed on or mounted to the support panel.

Furthermore, and as can be more clearly seen in FIG. 5 of the drawings,the horizontal leg and opposite lateral legs reside at the straightbottom edge of a semi-circular opening through the thickness of thesupport panel that is formed when the claw is partially punched outtherefrom and bent outwardly along the straight bottom edge of theopening. The openings associated with the claws are also provided toallow the mortar or cement to enter therethrough and wrap around thesteel support panel on the inner surface thereof. Thus, with theparticular configuration of the claws of the present invention, themortar will form a strong mechanical bond to the claws of the steelpanel to interlock therewith.

Preferably, and as shown in FIG. 3 of the drawings, the preferreddimensions of the various components of each claw is as follows: Thedepth of the horizontal leg is preferably 0.125 inches; the width of theclaw is preferably 0.8125 inches; the width of the pocket defined by thehorizontal leg and the opposite lateral legs is preferably 0.4375inches; the depth of the pocket measured between the outermost edge ofthe horizontal leg and the innermost edge of each lateral leg ispreferably 0.125 inches; the width of each lateral leg measured at itsfree end is preferably 0.125 inches; the width of each lateral legmeasured in proximity to the outer surface of the support panel ispreferably 0.16531 inches; the distance which the lateral legs extendoutwardly from the outer surface of the support panel is preferably0.375 inches; and the spacing between the free ends of the oppositelateral legs is preferably 0.1875 inches.

Furthermore, as can be seen in FIG. 5 of the drawings, the horizontalleg and the lateral legs of the claw form an acute angle with the outersurface of the panel of preferably 76 degrees. This particular angle ischosen so that the lateral legs of each claw can support the brick aboveit on the lower surface of the brick, and yet provide a triangular area(in cross-section) defined by the outer surface of the support panel,the lower surface of the brick and the inner surface (facing the supportpanel) of the horizontal leg and the lateral legs of the lower claw onwhich the brick may rest to receive mortar to insure that the brick issecured not only to the support panel but also to the mortar, and suchthat the mortar surrounds each brick mounted on the support panel.

Preferably, the vertical spacing between claws on the support panel isapproximately 2⅝ inches to allow a standard sized brick (or brickveneer) to be placed between the lateral legs of a lower claw and thelateral legs of an adjacent upper claw, as shown in FIG. 5.

FIG. 6 shows a top view of the support panel and claws, with a brickplaced against the outer surface of the panel. It should be noted fromFIG. 6 that the horizontal spacing between adjacent claws is selectedsuch that a single, standard sized brick or brick veneer is supportedby, and extends across, several claws on the support panel.

The masonry support panel of the present invention is preferably used inthe following manner. The support panel is attached to the wall of thebuilding or structure (covered beforehand with a building wrap) by usingfasteners placed through the spaced apart holes formed in the verticalstiffening ribs. Then, a dab of adhesive is placed in the four cornersof the brick, and the brick is positioned on and adheres to the outersurface of the support panel between vertically adjacent claws andpreferably supported by and resting on the outermost edges of thelateral legs of the claw or claws directly below it. One or more rows ofbricks are applied to the support panel in this manner. Then, mortar orcement is added to the vertical spaces and the horizontal spaces betweenadjacent bricks, that is, where the claws are also located. Thus, themortar not only forms a strong bond with the bricks, but alsomechanically interlocks with the claws of the support panel.

The support panel of the present invention accomplishes three primarygoals and overcomes the disadvantages of prior masonry support systems.First, the support panel of the present invention, with its verticalstiffening channels, keeps the panel away from the wall of the buildingor structure and thus provides a cavity for air and moisture to flowbetween the wall and the support panel. Second, the stucco-embossedtexture, which may be formed on either or both of the inner and outersurfaces of the support panel, promotes moisture flow between thesupport panel and the wall of the building or structure and the supportpanel and the brick attached thereto. Third, the particular shape of theclaws of the support panel of the present invention promotes a strongmechanical bond between the mortar and the support panel so that the twostrongly interlock with one another.

It should be realized, of course, that the particular dimensions andspacing of the claws on the support panel may be changed to accommodatebricks or stone, or different types of masonry, of various sizes, andthe spacing between the vertical stiffening channels may also vary topermit attachment of the support panel to a wall of a building orstructure in order to accommodate a different spacing between studs orother supporting structure used in a building, or to address differentstiffening requirements. Also, the support panels may be formed ofdifferent gauge steel than the preferred gauge disclosed herein toprovide sufficient strength and rigidity to support the masonry attachedthereto.

Although illustrative embodiments of the present invention have beendescribed herein with reference to the accompanying drawings, it is tobe understood that the invention is not limited to those preciseembodiments, and that various other changes and modifications may beeffected therein by one skilled in the art without departing from thescope or spirit of the invention.

1. A support panel for masonry objects, comprising: an inner surface; anouter surface; at least one stiffening channel formed longitudinallyalong the support panel; a plurality of substantially c-shaped clawsextending from the outer surface, the claws being disposed in spacedapart relation to one another to form a grid, wherein the claws areconfigured to contactingly support at least a portion of a masonryobject; and wherein the support panel is attachable to a wall of astructure via at least one fastener inserted into through the at leastone stiffening channel into the wall of the structure such that thepanel is spaced apart from the wall of the structure.